Custom Plastic Fabrication Services

A plastic fabricator designs, shapes, and finishes plastic materials into custom parts and products. This includes processes like thermoforming, vacuum forming, CNC trimming, heat bending, drilling, bonding, and assembly. Fabricators work from engineering drawings or CAD files to produce components for industries such as aerospace, medical, telecommunications, and industrial OEM manufacturing, handling everything from one-off prototypes to high-volume production runs.

Common plastic fabrication methods include thermoforming and vacuum forming (heating and shaping plastic sheets over a mold), CNC trimming and routing (precision cutting to drawing specs), heat bending and drape forming, bonding and adhesive assembly, precision drilling, and fastener installation. The best method depends on material type, part complexity, tolerances, and production volume. Hill Plastics utilizes all of these processes within a single 20,000+ sq ft facility.

Hill Plastics works with a wide range of thermoplastic sheet materials including ABS, High-Density Polyethylene (HDPE), PETG, High Temperature ABS, UV Resistant ASA/ABS, Polystyrene (PS), KYDEX, and decorative foil laminated materials. Material selection is guided by application requirements such as impact resistance, durability, chemical resistance, tensile strength, and environmental exposure to ensure the best performance and cost outcome.

Yes. Hill Plastics supports the full production spectrum — from single prototypes using low-cost wood or polyurethane tooling to large-volume runs using their 4'x7' Rotary Thermoforming machine, which operates 2.5x faster than standard single-station equipment. With over 20,000 sq ft of manufacturing space and eight thermoforming machines, they scale efficiently from design review through high-volume fulfillment.

Prototype lead times vary by design complexity, but Hill Plastics can typically produce a master pattern in just a few weeks. Once the wooden master pattern is CNC milled to print specifications and mounted on a mold base, prototype parts follow shortly after. The process allows for design adjustments before production approval, minimizing costly changes downstream and accelerating your time to market.

Hill Plastics serves a broad range of industries including aerospace and aviation, telecommunications, medical devices and healthcare, industrial equipment and OEM manufacturing, defense and military, point-of-purchase and retail display, marine, electronics, oil and gas, and transportation and logistics. Their 45 years of experience serving diverse sectors makes them a versatile fabrication partner for both established manufacturers and new product developers.

Yes. The sales and engineering team — Brad Hill and Cody Hill — provides full design and material selection assistance. They evaluate your application requirements including cost targets, impact needs, chemical resistance, and environmental conditions to recommend the right material and tooling approach. From concept to finished product, they offer turnkey guidance ensuring precision, functionality, and cost-effectiveness at every stage of the process.

Hill Plastics is headquartered at 1415 Crescent Ave., Lewisville, TX 75057 — conveniently located in the Dallas/DFW area. The company ships and serves clients across the United States, supporting OEM manufacturers, aerospace firms, telecom companies, medical device makers, and industrial clients nationwide. Their central Texas location allows efficient logistics for both regional and cross-country production fulfillment.